Capacitor forming method

ABSTRACT

The capacitor forming method utilizes a plurality of metal sheet manipulating rollers and a glass supply, which, in combination, make a metal-glass laminate and glass or devitrifying glass dielectric to form a capacitor. Several embodiments of the method manufacture ferroelectric crystal dielectrics by utilizing heat-treatment and annealing to form and devitrify glass while the glass is in a metal-glass spool or flat form.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to passive electronic components, andparticularly to a capacitor forming method and to a capacitor formedthereby.

2. Description of the Related Art

It is difficult to “capture a glass” made from a hot melt with achemical composition that is the same as a ferroelectric crystal. When ahot melt made of ferroelectric metal oxides is cooled slowly, it can beexpected to rapidly crystallize into a solid crystalline mass. By fastcooling this composition from a 1400° C. liquid melt, such as when thehot melt is poured directly into water, one can capture a glass (i.e., aviscous liquid), or ferroelectric glass. However, when this glass isquenched in water, the glass shatters into small pieces. Generallyspeaking, a useful glass shape cannot be formed by quenching in water.

Thus, a capacitor forming method solving the aforementioned problems isdesired.

SUMMARY OF THE INVENTION

The capacitor forming method uses a plurality of metal sheetmanipulating rollers and a glass supply in combination to manufacture ametal-glass laminate and a glass or devitrifying glass dielectric,thereby forming a capacitor. Several embodiments of the methodmanufacture ferroelectric crystal dielectrics by performingheat-treatment and annealing steps to form and devitrify glass while theglass is in a metal-glass spool or flat form.

These and other features of the present invention will become readilyapparent upon further review of the following specification anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic side view of an apparatus forming a capacitoraccording to a first embodiment of a capacitor forming method accordingto the present invention.

FIG. 2 is a partial diagrammatic side view of an exemplary capacitorformed by the capacitor forming apparatus and method of FIG. 1.

FIG. 3 is a diagrammatic side view of an apparatus forming a capacitoraccording to a second embodiment of a capacitor forming method accordingto the present invention.

FIG. 4 is a partial diagrammatic side view of a capacitor formed by thecapacitor forming apparatus and method of FIG. 3.

FIG. 5 is a diagrammatic side view of an apparatus forming a capacitoraccording to a third embodiment of a capacitor forming method accordingto the present invention.

FIG. 6 is a partial diagrammatic side view of a capacitor formed by thecapacitor forming apparatus and method of FIG. 5.

FIG. 7 is a diagrammatic side view of and apparatus forming a capacitoraccording to a fourth embodiment of a capacitor forming method accordingto the present invention.

FIG. 8 is a diagrammatic side view of an exemplary capacitor formed bythe capacitor forming apparatus and method of FIG. 7.

FIG. 9 is a diagrammatic side view of an apparatus forming a capacitoraccording to a fifth embodiment of a capacitor forming method accordingto the present invention.

FIG. 10 is a diagrammatic side view of an exemplary capacitor formed bythe capacitor forming apparatus and method of FIG. 9.

Similar reference characters denote corresponding features consistentlythroughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The capacitor forming method uses a plurality of metal sheetmanipulating rollers and a glass supply in combination to manufacture ametal-glass laminate and a glass or devitrifying glass dielectric,thereby forming a capacitor. Several embodiments of the method makeferroelectric crystal dielectrics by utilizing heat-treatment andannealing to form and devitrify glass while the glass is in ametal-glass spool or flat form.

All embodiments of the capacitor forming method are intended to work aglass that devitrifies to a ferroelectric with a high dielectricconstant. Glass is formed with a metal foil ribbon that runs at highspeed on a flat bed or in a spool, thereby creating a laminate. Thelaminate has heat-soaking properties that encourage the growth of smallferroelectric crystals within the glass (a process calleddevitrification). The method does not perform heat-treatment onnon-devitrifying glass. However, the method heat treats a devitrifiableglass after the glass is formed with a metal ribbon into a capacitor orsuper-capacitor laminate.

The method utilizes a moving, liquid glass quenching (viscosity-100 to1000 Poises) metal foil ribbon that combines with the liquid glass. Themethod uses a roller to spread the glass-foil combination into a thinlayer, the roller pressing against the metal foil as it guides over anopposing cooling roller. In this manner, the method laminates multiplelayers of metal foil and glass together. The glass intended to bedevitrified will grow micro-crystals that are ferroelectric with a highdielectric constant, after it is captured and formed as a glass. Themetal foil in motion draws heat rapidly from the glass while it is stillfluid to drop the temperature of the glass by 200° C. to 300° C. andthereby prevent early devitrification. As the glass is cooled to theworking point temperature (a viscosity of about 10,000 Poise), theglass-to-metal foil forming is completed. At this working temperature,the glass-metal laminate (for a devitrifying glass) can begin heatsoaking using a roller kiln or kiln provided by the capacitor formingmethod to cause small ferroelectric crystals to slowly grow within theglass. After the method completes heat treatment, the method controls atemperature-controlled kiln (Lehr) to slowly lower the temperature ofthe laminate to room temperature.

The design requirements to create ferroelectric crystals in amanufacturing apparatus to make a capacitor are described next. Thevarious embodiments of the capacitor forming method described hereinprovide means for fabricating a ferroelectric glass into a capacitor ora super-capacitor.

While using a moving metal foil to contact a controlled amount of hotmelt, the glass melt can be quenched to form or capture a crystal-freeglass as it is coated on the metal ribbon and formed into a laminate.The metal will absorb heat to help a melted “ferroelectric” compositioncool to become captured “as a glass”. The melt contacts the metal foilin a hot condition at near 100 poise (where the melt flows like water)in viscosity, and then is rapidly dropped in temperature to 10,000 poiseto avoid devitrification, and still form a useful shape for the glass atthe working point temperature (10,000 poise).

The moving metal foil is also cooled as it moves over a cooled roller,as the metal foil and roller contact the hot melt.

Oxygen stealing additives, like B₂O₃ or Al₂O₃, in the chemicalcomposition should be used in the chemical formulation to slow downcrystal growth as the glass is cooled.

Delivery of the hot melt to the forming apparatus uses a movable vesselor capsule directly above each metal foil/hot glass squeezing station.The capsule must be insulated in design to hold the melt at a hightemperature to prevent devitrification. As the melt temperature drops,it tends to be more viscous and difficult to pour. Various means of spotheating are known to glass technicians practiced in the art, who canadjust the heat and viscosity of the flowing hot glass.

There is a short window between the liquid melt and working temperature.The cooling effect of the metal foil does not extend over a longtemperature span. During a temperature drop of 200° C. to 300° C., theglass can be formed into a useful shape. The glass must drop only200°-300° C., while the metal must gain in heat from 30° C. to 950° C.

The forming apparatus may use low cost metals, such as OFHC copper orbrass, that can quench a melt at 1050° C. down to the “working pointtemperature of 940° C. Special nitrogen or other non-oxygen bearingatmospheres are needed in the follow-on processes if low cost metals areused.

After forming a useful glass-metal shape near the working pointtemperature for a ferroelectric glass, the heat soaking process canbegin immediately to begin growing ferroelectric crystals. Annealing toroom temperature would now start for a glass not intended to bedevitrified. However, for a glass intended for devitrification, a slowheat-soak, perhaps lasting several hours, may be needed to grow thenecessary small microcrystals within the glass. For example, in thethird embodiment of the method, described below, the heat soakingprocess can begin on a production roller kiln as soon as the laminate isformed. After some devitrification to gain stiffness, cutting the flatlaminate into pieces with a laser would then permit stacking of thesepieces on kiln cars that pass through a large tunnel kiln, as would beneeded to complete the heat-soaking process. After heat soaking, thelaminated product should be slowly cooled to room temperature by movingthe loaded car in the tunnel kiln directly into a Lehr oven designed toaccept the same kiln car.

Five production designs provide fast quenching of devitrifiable glassthat has first been formed as a glass within a glass-metal laminate inthe shape of a spool or flat laminate. They are fast, volume producingapparatus for the manufacture of a capacitor or super-capacitor. By fastforming a glass or a devitrifiable glass into a glass-metal laminatewhile the melt drops in temperature down to the “working pointtemperature” of the glass, the glass is thereby formed while still fluidenough to be “worked”. Slow devitrification can begin immediately afterforming.

The production designs described herein use a moving, metal-foil ribbonto contact a controlled amount of hot glass. This provides rapid formingand quenching of the glass, which is required to secure a glass withlimited or no crystalline content, while spooling or flat forming theglass into of a metal-glass laminate. In this process the glass issqueezed at high speed into a thin dielectric layer, common to capacitordesign. Rapid cooling of the glass melt is aided by the heat that can beabsorbed by the many metals that may be used in this apparatus, comparedto the heat in the glass.

TABLE I Material Relative Heat Absorbing Rate Platinum 3.0 Copper (Cu)3.45 Iron (Fe) 3.5 Glass 0.75

The capacitor forming method can use special thermal control techniquesto manage the volume of glass flowing into contact with the metal foilribbon to be squeezed to the proper thickness. These heat controlmethods are commonly known and used by glass technicians, who can coolor heat small areas on the hot glass as it flows from the movablecartridge into the roll squeezing area (cooled roller and moving metalribbon).

The capacitor forming method utilizes a movable cartridge containing“melted and refined glass” to dispense liquid glass continuously ontothe site above the metal foil ribbon that moves on compression rollersmade of high carbon iron or graphite. The cartridge must include aceramic insulated liner on the outside or inside of a shell made of asuitable metal, such as Kovar or platinum.

The capacitor forming method utilizes forming rollers that do not stickto molten glass. Materials like graphite and high carbon iron are commonto the glass molding industry, where hot glass and formed glass shapesdo not stick to the forming molds.

The capacitor forming method uses alternative high-temperature resistantmetal ribbon that can withstand the ferroelectric-melt pouringtemperature. The best possible metal ribbon may be made of platinum.Metals that may be considered for this process design include: platinum,gold-clad nickel, 304 stainless steel, Hastelloy C, Kovar, nickel,selected brass compositions and OFHC copper, and have a ribbon thicknessbetween 0.0003 and 0.003 inches, and preferably near 0.001 inches inthickness. Some metals may be pre-oxidized and perhaps pre-borated forglass wetting. The use of a metal ribbon 0.001 inches in thickness orless will negate the expansion coefficient difference between glass andmetal.

The coefficient of thermal expansion for most metals may besignificantly higher than the glass or devitrified glass. By selectingthin metal foil, a metal, such as platinum, if annealed, will yieldunder stress caused by the expansion and contraction differences withthe glass. Platinum is expensive, but is expected to work well in thisapplication. During high temperature heat treating for the other metalsavoid the oxidation of Kovar and stainless steel by using a nitrogenatmosphere. Copper is not very refractory and would also require anon-oxygen atmosphere in the heat-treating kilns.

The capacitor forming method utilizes a ferroelectric glass composition,like barium oxide and titanium dioxide that can be refined andpre-melted off site or away from the apparatus. The melted compositionmust be delivered in a sliding or movable capsule to deliver hot melt inan unending flow to the pour area.

The capacitor forming method may use different metal foil types andvarious devitrifying ferroelectric glass composition or standardnon-devitrifying glass formulations that, when squeezed together, make auseful product at a fast rate when forming a metal-glass-metal sandwichinto a flat or spooled form. Heat treating is used to devitrify theglass that can form into high dielectric constant ferroelectric crystalsof small size, which are embedded within the remaining glass phase.

The capacitor forming method utilizes formulations of glass not intendedto devitrify. All glasses, including those intended to be devitrified,must have very high surface and volume resistivity to hold an electriccharge within the dielectric for a long period of time. The electricalcharge, once loaded in the dielectric, must not bleed away easily withthe passing of time. The chemical formulae for glasses that achieve highvolume and surface resistivity are needed for this production, but thistechnical data is not made public. This data is not reported in publictechnical publications.

Electrical parameters must be considered proprietary to any seriouscommercial enterprise. The resistivity (ohm-cm) of the dielectric mustapproach or exceed 10¹⁷ ohm-cm when measured in the temperature rangefrom 30° C. to 120° C. For a non-devitrified glass, an achieveddielectric constant for a glass dielectric might be 15, and combinedwith high resistivity, this glass could be quite valuable for the smallcapacitor or printed circuit board market. But the preferred materialwill have a uniform higher dielectric constant between 2000 and 20000+for the temperature range from 30° C. and 120° C. and will be amicrocrystalline ferroelectric made from glass, as described here. Ifthis glass-formed ferroelectric also has a high resistivity and high DCbreakdown resistance, this chemical formulation will make an energystorage method to compete strongly with batteries.

After forming and annealing the final laminated assembly to roomtemperature, the common metal electrodes that extend out from thefabricated capacitor may be cleaned, welded together and thenelectrically connected to a female plug-in electrical terminal to allowsafe electrical connection when a high voltage is stored in thiscapacitor or super-capacitor. To complete steps intended to manufacturethis product, the laminate assemble could then be dipped in a dielectricpolymer and molded in a polymer jacket to form a super-capacitor orcapacitor as a final product.

It is contemplated that the final product will hold an electric chargefor an extended period for time, and will do so because the resistivityof the starting glass composition or devitrified glass is higher than10¹⁷ ohm-cm at ambient temperatures. Similarly, if the dielectricconstant and the breakdown voltage of the final glass or devitrifiedglass are high and uniform in value with change in temperature from 30°C. to 120° C., this production system may eliminate lithium batteriesand IC engines in cars and trucks that use gasoline and diesel fuel.

A fast production method of forming devitrified glass ferroelectriccapacitors is presented herein. The design apparatus needed tostreamline the production of a devitrified glass-metal foil capacitorhas heretofore never been advanced. When viewing a huge market, unitcost is major. The volume of super-capacitors needed for the autoindustry alone is between 10 and 40 million units per year. It is glassforming at 25% the cost of ceramic forming that will make glass forminga winner.

In a first embodiment of the capacitor forming method, as shown in FIG.1, a lowest point spool 10 takes up a three metal foil-two glass layercomposite ribbon 13 while concurrently taking up a ribbon 12 comprisinga single metal foil coated on both sides with glass. Preferably thespool 10 has an outer thin ceramic ramp surface 14. The ribbons 12 and13 being spooled by lowest point spool 10 are insulated and heldtogether by an adhesive 16, preferably Sauereisen cement No. 1.

Ribbon 12 originates from a spool 32 that is disposed above movable hotglass cartridges 40. Liquid glass flowing out of glass cartridges 40 ispressed onto the metal ribbon by rollers 20 a and 20 b to form thecoated ribbon 12. The liquid glass is constrained by platinum bin 41,which funnels the liquid glass proximate the glass pressing location.

The composite ribbon 13 includes a central metal foil component thatoriginates from spool 34 above removable or moving hot glass cartridges36 a and 36 b. The volume of viscous glass dispensed from cartridges 36a and 36 b is constrained by pinching rollers 26 a and 26 b. Lateralsurface metal foil components are dispensed from foil spools 28 and 30and are guided by rollers 22 and 24. The pressing operation that formscomposite ribbon 13 is accomplished via spools 18 a and 18 b, which arepreferably air or water-cooled graphite or high carbon iron rollers.After one of these two locations, the glass-metal-glass is immediatelysqueezed between two metal foils, and then spooled. The otherglass-metal-glass is wound on the spool. The process performed by theapparatus 100 and capacitor forming method forms a spooled supercapacitor having negative plate layers 202 and positive plate layers 204separated by dielectric material, as shown in FIG. 2, 200. The spooledlaminate must then be immediately heat soaked as in a tunnel kiln andcooled in Lehr as described for the laminate formed in FIG. 5 byapparatus 500.

In capacitor forming device 300, two metal foils sandwich a glass layeron the left, and one metal foil is coated on both sides with glass onthe right. Both are wound on the spool, thereby forming a spooledcapacitor. As most clearly shown in FIG. 3, the glass coated foil ribbon12 is combined with a foil coated glass ribbon 39. The two foil coatsfor ribbon 39 originate at spools 308 and 34, the foil coats beingguided by guide rollers 302 and 304, respectively, before being pressedto the glass by pressing rollers 18 a and 18 b, respectively. The glassflow originates from moving or removable hot glass cartridge 306. Thespooled laminate must then be immediately heat soaked as in a tunnelkiln and cooled in a Lehr, like the laminate formed in FIG. 5. As shownin FIG. 4, the spooled capacitor 400 has negative plates 402 andpositive plates 404 separated by a dielectric.

A five metal foil are coated with glass by apparatus 500, shown in FIG.5. A roller or belt driven forming table is used to initially form thelaminate. Then the laminate moves on to a roller kiln to heat-soak theglass. After an initial heat soak, the flat laminate may be “laser cut”into useful shapes. The cut shapes may be reloaded onto tunnel kiln carthat can also fit into a Lehr oven. After the heat soak is completed inthe tunnel kiln the car can be rolled into a Lehr, for the purpose ofannealing the assembly (slow cooling) the laminate back to roomtemperature. As most clearly shown in FIG. 5, the hot glass is sourcedfrom cartridges 520, 522, 524, and 526. Each of the cartridges has anaperture to allow air to be infused into the hot glass. Metal foiloriginating spools 550, 552, 553 and 556 dispense metal foil thatcombines with glass from cartridges 520, 522, 524, and 526,respectively. Respective guide rollers 540, 542, 544, and 546 are usedto pretension the metal foil before it is threaded throughcooling-laminate applying roller combinations 534 a-534 b, 532 a-532 b,530 a-530 b, and 528 a-528 b. Glass surfaces 512, 514, 516 and 518encapsulate the foil layers associated with subsequent dispensingcartridges in the laminate series. Glass layer 518 is combined with abase metal foil dispensed at approximately 1 foot per second from basespool 570 and is guided by metal roller 572 to add the fifth layer tothe capacitor. A flat bed of rollers 502 holds the foil-glass mix in aflat configuration while undergoing forced air cooling. The forced aircooling preferably rapidly drops viscosity of the glass to approximatelylog 10⁴⁻⁵ poise to start the devitrification process. The foil-glass mixis continuously fed over the flat bed of rollers 502 by a water-cooleddrive roller 573. An approximately 2000-foot long portion of the flatbed rollers 502 extends through a heat-treating kiln 574 that allowsdevitrification of the foil-mix to proceed. Preferably roller kiln 574holds the foil-mix to between approximately 600° C. and approximately900° C. for approximately thirty minutes. A laser cutter 576 is disposedover the foil-mix downstream from roller kiln 574 and cuts the foil-mixinto desired capacitor form factors. The flat form factors are loaded ona kiln car for travel through tunnel kiln 578 and a Lehr kiln 580arranged further downstream to complete slow devitrification and coolingthe capacitor glass sheets 504, 506, 508, and 510 to 30° C.,respectively.

The process makes a super capacitor 800 of a flat design, which isdetailed in FIG. 6. The negative metal 802 is followed by a neutralmetal 803, which is followed by a positive metal 804, dielectricmaterial being disposed between the metals. The pattern is repeated forthe extent of the capacitor.

FIG. 7 shows a simple capacitor forming apparatus 700. A platinum trough726 used to hold hot glass 724 has a pair of flanges 727, which areattached to support beams 722, thereby providing support to the trough726. The trough 726 is not intended to be mobile because it is bigenough to be a reservoir into which melted glass can continuously flowfrom a specialized melting unit.

A resistance wire 725 is disposed in the trough 726. When the resistancewire 725 is electrically energized, it heats the glass 724 within thetrough to keep the glass 724 fluid and flowing downstream. Theconfiguration of trough 726 and pressing rollers 714 a and 714 b withrespect to quick change metal foil roll 710, metal foil roll 712, metalfoil roll 716, and quick change metal foil roll 718 provides controlover a small volume of glass as it is brought into contact with a movingmetal foil or foils, thereby forming a useful capacitor product.

The configuration of pressing rollers 714 a and 714 b precisely controlsthe volume of the glass melt traveling downstream through the mechanism,thereby allowing the glass to be fluid enough so that it flows to fillthe void between the metal foils 720, while also dropping rapidly intemperature by about 200° C. to 300° C. as the glass comes in contactwith the cooling metal foil and backing roller. The process preventsdevitrification, yet allows sufficient time to allow the glass to takeshape between the metal ribbons while the glass is still about 10,000Poise in fluidity. Flow downstream of the metal-glass-metal laminate 702is guided by a plurality of guide rollers 708 until the laminate 702 ispressed and guided by upper rollers 706, 704 b, along with lower rollers704 a. The formed laminate must be given follow-on roller kiln heattreatment for devitrification, laser cutting of the laminate, heat soakin a tunnel kiln and Lehr cooling, as described in devices 500 in FIG.5.

Thus, the apparatus controls the volume of glass and controls the metalfoils to quench and shape the glass to form the metal-glass-metallaminate capacitor 800 shown in FIG. 8.

As shown in FIG. 9, two capacitors can be formed back-to-back bycombining two of the platinum trough devices 700 to hold the hot glass724.

The troughs 726 are not intended to be mobile. They must have sufficientvolume to form reservoirs that hold enough melted glass 724 to providetemperature control and flow control, yet provide for the continuousrefill and flow from a specialized melting unit.

A resistance wire 725 is used as a heater in the trough to keep theglass fluid and flowing. The method of controlling and delivering asmall volume of glass that can be continuously quenched (i.e., reducedin temperature) when it is brought into contact with moving metalfoil(s) is the same as the method described above with respect to thedevice 700. First and second individual laminates are pressed by rollergroups 916 a, 916 b and 918 a, 918 b, respectively. The first and secondlaminates are then joined downstream by laminate joining rollers 914 aand 914 b to form the dual laminate back-to-back capacitors 1000, shownin FIG. 10. Drive roller 706 and roller systems 704 a and 704 b maintaina flat laminate configuration 902. This laminate form must then be heattreated in a roller kiln, undergo laser cutting, tunnel kiln heat soakand Lehr cooling as described in devices 500 of FIG. 5.

In summary, the technology proposed here defines a manufacturingapparatus and a series of processing steps needed to automate themanufacture of a capacitor with a special dielectric. The formingtechnology presented here is very different from a slow, hot pressceramic forming method now being marketed for the same ferroelectric,BaTiO₃. A major advantage of a devitrified glass derived ferroelectricis that there is no porosity. Unfortunately, ceramic-formedferroelectric crystals have pores around them. The estimated unit costto make a ceramic ferroelectric is probably higher by a factor of 4×.Technical performance for the ceramic in terms of holding an electricalcharge is not projected as good as a devitrified glass approach.

It is to be understood that the present invention is not limited to theembodiments described above, but encompasses any and all embodimentswithin the scope of the following claims.

1. A capacitor forming method, comprising the steps of: forming a firstdielectric sheet from viscous glass material, the first dielectric sheethaving a first and a second surface; rolling a first thin metal foilonto the first surface of the first dielectric sheet while the firstdielectric sheet is in a semi-viscous condition; rolling a second thinmetal foil onto the second surface of the first dielectric sheet whilethe first dielectric sheet is in a semi-viscous condition; forming asecond dielectric sheet from viscous glass material, the seconddielectric sheet having a first and a second surface; and rolling athird thin metal foil into the second dielectric sheet while the seconddielectric sheet is in a semi-viscous condition, the third thin metalfoil being disposed approximately halfway between the first and thesecond surfaces of the second dielectric sheet; cooling the dielectricsheets concurrently with the thin metal foil rolling steps; andcombining the first and the second dielectric sheets, thereby forming acapacitor.
 2. The capacitor forming method according to claim 1, furthercomprising the step of rolling a fourth thin metal foil into said firstdielectric sheet while said first dielectric sheet is in a semi-viscouscondition, said fourth thin metal foil being disposed approximately halfway between said first and said second surfaces of said first dielectricsheet, the fourth thin metal foil being interposed between said firstand said second surfaces of said first dielectric sheet, whereby a supercapacitor is formed.
 3. The capacitor forming method according to claim1, further comprising the step of rolling said capacitor into a spool.4. The capacitor forming method according to claim 2, further comprisingthe step of rolling said super capacitor into a spool.
 5. The capacitorforming method according to claim 1, wherein the viscous glass materialis a devitrifying glass material.
 6. The capacitor forming methodaccording to claim 5, wherein the devitrifying glass material is aferroelectric material.
 7. A capacitor forming method, comprising thesteps of: forming first, second, third and fourth dielectric sheets ofviscous glass material, each of the sheets having a first and a secondsurface; rolling a first thin metal foil onto the first surface of thefirst dielectric sheet while the first dielectric sheet is in asemi-viscous condition; rolling a second thin metal foil onto the firstsurface of the second dielectric sheet while the second dielectric sheetis in a semi-viscous condition; rolling a third thin metal foil onto thefirst surface of the third dielectric sheet while the third dielectricsheet is in a semi-viscous condition; rolling a fourth thin metal foilonto the first surface of the fourth dielectric sheet while the fourthdielectric sheet is in a semi-viscous condition; combining the first,the second, the, third, and the fourth dielectric sheets, the firstdielectric sheet being on a top layer, the fourth dielectric sheet beingon a bottom layer; rolling a fifth thin metal foil onto the secondsurface of the fourth dielectric sheet while the fourth dielectric sheetis in a semi-viscous condition, thereby forming a five metal foil-glasslaminate; cooling the dielectric sheets concurrently with the thin metalfoil rolling steps; heat-soaking the glass portion of the five metalfoil-glass laminate; and annealing the five metal foil-glass laminate,whereby a super capacitor in a flat configuration is formed.
 8. Thecapacitor forming method according to claim 7, further comprising thestep of infusing cooling air directly onto the glass dielectric sheets.9. The capacitor forming method according to claim 7, wherein a rolldispensing rate of said fifth metal foil is approximately one foot persecond.
 10. The capacitor forming method according to claim 7, furthercomprising the step of subjecting said five metal foil-glass laminate toforced air cooling before the start of the devitrification process. 11.A capacitor forming method, comprising the steps of: forming a firstdielectric sheet from viscous glass material, the first dielectric sheethaving a first and a second surface; rolling a first thin metal foilonto the first surface of the first dielectric sheet while the firstdielectric sheet is in a semi-viscous condition; rolling a second thinmetal foil onto the second surface of the first dielectric sheet whilethe first dielectric sheet is in a semi-viscous condition; constrainingthe first dielectric sheet to a small volume, thereby allowingcontinuous quenching of the first dielectric sheet when the firstdielectric sheet is brought into contact with the first and second thinmetal foils; and heat soaking the first dielectric sheet therebydevitrifying the first dielectric sheet.
 12. The capacitor formingmethod according to claim 11, further comprising the steps of: forming asecond dielectric sheet from viscous glass material, said seconddielectric sheet having a first and a second surface; rolling a thirdthin metal foil onto said first surface of said second dielectric sheetwhile said second dielectric sheet is in a semi-viscous condition;rolling a fourth thin metal foil onto said second surface of said seconddielectric sheet while said second dielectric sheet is in a semi-viscouscondition; constraining said second dielectric sheet to a small volume,thereby allowing continuous quenching of said second dielectric sheetwhen said second dielectric sheet is brought into contact with saidthird and fourth thin metal foils; combining said first dielectric sheetwith said second dielectric sheet; and heat soaking said seconddielectric sheet thereby devitrifying said second dielectric sheet. 13.The capacitor forming method according to claim 11, wherein a capacitoris formed in a flat configuration.
 14. The capacitor forming methodaccording to claim 11, wherein said quenching of said first dielectricsheet drops a temperature of said first dielectric sheet byapproximately 200° C. to 300° C.
 15. The capacitor forming methodaccording to claim 12, wherein a plurality of back-to-back capacitors isformed in a flat configuration.
 16. The capacitor forming methodaccording to claim 12, wherein said quenching of said second dielectricsheet drops a temperature of said second dielectric sheet byapproximately 200° C. to 300° C.